Multi-Function End Effector for Fastener Continuity Testing
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Solution Overview
Problem
Current methods for verifying electrical grounding of fasteners in aircraft are manual, time-consuming, and prone to errors, making it impractical to check the electrical resistance of each fastener due to the large quantity involved.
Innovation Solution
A multi-function end effector mounted to a movable platform that integrates a continuity tester to automate the process of verifying electrical continuity between fasteners and the structure, allowing for accurate resistance measurements during fastener installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual resistance measurement methods are used to verify electrical grounding of fasteners, then measurement capability is achieved, but the process becomes time-consuming and error-prone due to the large quantity of fasteners
Solution Approach 1:
The fastener installation tool automatically performs electrical continuity testing during the fastener installation process itself. The system uses the installation tool's inherent electrical connection to the fastener to measure resistance, eliminating the need for separate manual verification operations. This integration allows the system to verify electrical grounding automatically as each fastener is installed, maintaining measurement accuracy while dramatically increasing verification throughput.
2Reliability
If manual resistance measurement is performed on each fastener, then electrical grounding verification is achieved, but the complexity and time required increases significantly
Solution Approach 1:
The patent combines the fastener installation function with the electrical continuity testing function into a single integrated tool. The installation tool includes both the mechanical fastening mechanism and the electrical measurement circuitry, allowing simultaneous or sequential execution of installation and verification operations. This merging eliminates the need for separate verification steps, reducing total time while maintaining reliable electrical grounding verification through automated measurement and reporting.
3Productivity
If automated testing is implemented to increase verification speed, then productivity improves, but device complexity increases
Solution Approach 1:
The fastener installation tool is designed with multi-functionality, serving both mechanical fastening and electrical continuity testing purposes. The tool includes universal electrical contacts that can measure resistance through various fastener types and structural configurations. By making the installation tool itself the testing instrument, the system achieves high verification throughput without requiring separate dedicated testing equipment, thereby limiting the increase in overall system complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables automated, accurate, and efficient verification of electrical continuity at each fastener installation, reducing the risk of errors and ensuring reliable grounding in aircraft structures.
Implementation Method 1
configured to measure a magnitude of electrical resistance of an electrical path between each fastener and the structure after installation of the fastener
Data Source
AI summary
A continuity testing system includes a continuity tester mountable to a movable platform capable of positioning the continuity tester relative to a structure. The continuity tester is configured to determine the existence of an uninterrupted electrical path between the structure and a fastener installed in the structure.